Means for forming hollow structures



2- c. A. JOHNSON 2,298,132

MEANS FOR FORMING HOLLOW STRUCTURES Filed Oct. 11, 1940 8 Sheets-Sheet 1 INVENTOR. ca /12455 A. JOHNSON ATTORNEY Oct. 6, 1942. c. A. JOHNSON MEANS FOR FORMING HOLL'OW STRUCTURES Filed Oct. 11, 1940 .8 Sheets-Sheet 2 INVENTOR. (HA/e425 AJo wso/v ATTORm/LY mm M w Mm Nb mm 11 Q Oct 1942- c. A. JOHNSON MEANS FOR FORMING HOLLOW STRUCTURES Filed 001;. 11, 1940 8 Sheets-Sheet 3 a I'll ATTORNE C. A. JOHNSON MEANS FOR FORMING HOLLOW STRUCTURES Filed Oct. 11, 1940 8 Sheets-Sheet 4 INVENTOR. CHARLES A- JOHMSON ill Oct. 6, 1942.

Oct. 6, 1942.

c. A; JOHNSON 2,298,132

MEANS FOR FORMING HOLLOW STRUCTURES Filed Oct. 11, 1940 8 Sheets-Sheet 5 INVENTOR. g/mews Adam/501V ATToRNaY '0t.'6, 194z. QAJQH SQN I 2,298,132

MEANS FOR FORMING HOLLOW STRUCTURES Filed Oct. 11, 1940 s Sheets-Sheet 6 IN VEN TOR.

7 76, la CHA 242.5 A- Jam/50M ATTORNEY Oct. 6, 1942. c. A. JOHNSON 2,298,132

MEANS FOR FORMING HOLLOW STRUCTURES Filed Oct. 11, 1940 8 Sheets-Sheet 7 iliiliil CHA ELES A. JOHNSON ATTORNEY Oct. 6, 1942. c. A. JOHNSON 8,

MEANS FOR FORMING HOLLOW STRUCTURES Filed Oct. 11, 1940 8 Sheets-Sheet 8 //7 /5 FIG. 24b INVENTOR.

cfiAeLfis A. JOHNSON ATTQRNELY Patented Oct. 6, 1942 {PATENT OFFICE 'rmans non FORMING-HOLLOW srancrunns Charles A. Johnson, Brooklyn, N. Y., assignmof one-half to Irving Seidman, New York, N. Y.

Application October 11, 1940, Serial No. 360,779

' 3 Claims. (01. 113-42) This invention relates to a method of and means for making hollow and tubular bodies and objects of predetermined. form, and more particularly to a novel and eflicient method of constructing airplane fuselages. wings, etc.

Broadly, it is an object of my invention to provide a cheap and simple method of making airplanes in which the independable factor of human skill is replaced by accurate mechanical devices and controls which combine to produce a light but sturdy alLmetal airplane of smooth exterior.

More specifically, it is an object of my invention to provide a method of manufacturing all welded metal airplanes by means of a simple split die in conjunction with other simple apparatus, thus eliminatingthe expensive male and female dies ordinarily used.

Another object of my invention is to produce astructure with welded joints or seams of maximum strength and ductility, such joints or seams being welded continuously throughout their entire length.

Another object of my invention is to provide a means for manufacturing all welded airplanes;

with an exterior free of the warping and distortion otherwise resulting from the intense heat generated in the welding operation.

Another object is to provide a means for forming in one operation the skin or shell of the wings and fuselage along with the fixed tail surfaces, while simultaneously cutting door, window, windshield, and other openings and access holes. I

Still another object is to utilize this invention in conjunction with my co-pending application, Serial No. 361,551 to produce an all welded metal airplane of fewer and simpler parts than those used in other methods of airplane manufacture.

In other methods of airplane manufacture, the metal skin or shell isvformed in sections such sections being then connectedtogether and to an interior structureor framework.'. Such connections are usually made by means of rivets orelec-.

. is. required to stamp out orfo'rin, in a separateoperation, each .of ,thelmanysections comprising the wing or fuselage. Not onlyare such dies very expensive but atrimming operation is generally required following'the stamping of the part.

In addition, the riveting of connections is a hand operation and therefore, a costly one. Rivets are sometimes poorly formed or'driven which necessitates a close inspection of all rivets, the removal of the faulty ones, and replacement by others.

Another objection to the use of riveted connections is the considerable wind resistance caused byprotruding rivet heads. This can be overcome only through a costly operation of countersinking rivet holes and flush finishing of rivet heads.

The resistance spot welding of seams, while increasing in use and popularity in airplane manufacture, possesses disadvantages too.

rivet heads.

An objection common to both riveting and spot welding is' the increased wind resistance caused by the projecting laps of the seams.

On the other hand, a continuously welded seam is impracticable under present methods of manufacture. Excessive warping and distortion develop from the intense heat generated in the welding process. This can be held to ,a minimum through a careful balance of current, timing, and good cooling, but warping and distortion have not yet been eliminated in the welding of such light gauges of metal such as are used in metal airplane manufacture.

Such warping or distortion of an air-plane's surface results in a low aerodynamic efliciency. It also decreases the compressive strength of the structure.

Furthermore, in the welding of high strength heat treated aluminum alloys, the weld is brittle and a zone of annealed metal is formed adjacent to the weld. The resulting connection is of very low strength.

With these and other objects in View, my invention consists in the method and combination hereinafter set forth and claimed, with the understanding that the various elements comprising the airplane or other articles in the manufacture ofwhich my method may be utilized,

may be varied somewhat in the shape ,of the Fig. 1 is a perspective view showing a split die 55 for forming or shaping airplane fuselages'with a portion of the die broken away to show in its interior those parts co-operating with the die to form the fuselage. I

Fig. 2 is a perspective view showing an airplane fuselage formed by the die of Fig. 1.

Fig. 3 is a longitudinal section taken vertically through the die of Fig. 1, showing the fuselage of an airplane before the forming operation.

Figs. 4a and 4b are transverse, sectional views taken on the lines 4-4 of Fig.3. Fig. 4a shows the fuselage before, and Fig. 4b shows the fuselage after forming.

Fig. 5 is a sectional view showing the rudder fin of the fuselage shown in Fig. 3 after forming.

/Figs. 6, 8 and are enlarged sectional views showing a portion of the die and the rudder fin of the fuselage shown in" Fig. 3 along with the 'means for forming the same.

Figs. '7, 9 and 11 are sectional views taken. respectively, on the lines 'I-l, 8-0, and ii-ii of Figs. 6, 8 and 10.

Figs. 6 and 'I show the tail assembly before the forming operation. 7

Figs. 8 and 9 show the tail assembly during the forming operation.

Figs. 10 and 11 show the formed tail assembly.

Fig. 12 is a" sectional view showing the interior of the forward portion of one-half the die shown in Fig.- 1.

Figs. 13 and 14 are sectional views illustrating a method of making one of the parts of my invention. 1 1

Fig. 15 is a erspective view showings split die for forming or shaping an airplane wing, with a portion of the die broken away to show in its interior those parts co-operating with the die to form the wing.

Fig. 16 is a perspective view showing an airplane wing formed by the die of Fig. 15.

1 and 's m 12 inclusive, are mews fianges I. on both halves of the mold 28 which run longitudinally around the mold.

Figs. 1, 3, 4a. 4b and 5 show clamps 2| ,fitting over the flanges 21 -to secure the halves of the mold a together, when properly mated, as shown in 1 8 1, 4a and 4b. I

Figs. 1, 3 and 12, I show a pipe I. with a or face plate 3i fitting a groove 32 running around the mold It as shown in Figs. 3

or casing 34 made of an elastic material, such as rubber, and fitting close to the v block ll forward of the tail section.

To best illustrate the operation of my invention! have omitted showing in Fig. 3 the tail section of the elastic sheath t4 and the block 33 with the interior mechanism.

For the same reason the tail section of the block a with the interior mechanism has been insure a tight joint a suitable cement or bonding .Fig. 1'7 is a fragmentary sectional view taken vertically through the die of Fig. 15 showing a wing of an airplane before the forming operation.

Figs. 18a and 18b are sectional views taken on thelines ll-ll ofFig. 17.

Fig. 184 shows a' wing before, and Fig. 18b shows a wing after forming.

Fig. 19 is a sectional view of the forward end of one-half the die of Fig. 1, showing an alternate agentmaybeused.

AisoshowninFig.3isalarge hole 38 passing through the sheath 34 and extendingpart way into the block. Radiating from the hole ll to the surface of the bloclr 33 are several smaller holesll communicating with hole 10.

ShowninFigs. 1,3,4aand tbisathin hollow metal form II.

Shown in Figs. ii, 4a and 4b, and 8 to 11 inelusive, is a shaft 3! running through the length arrangement of the parts shown in the forward end of Fig. 3.

Figs. 20, 21 and 22 are sectional views showing the forces involved in forming an airplane fuselage or wing in the way of a welded seam that has been previously beveled on' its outer side.

These sections also show the progressive'stages in' cutting the metal.

Fig. 23 is a view showing the interior of a por-' tion of one-half a die.

Figs. 24 and 246 are sectional views taken w onthe lines 24-24 of. Fig. 23 and show in addition co-operating apparatus within the die.

Figs. 23, 24a and 24b show means for the mechanical lubrication of the interior of the die and for the deep drawing and cutting of a por- 65 tion of a fuselage shell.

Fuselage and fin construction Referring to the drawings, Figs. .1, 4a and 4b show a hollow mold 28, while Fig. 3 shows onehalf the mold 26. for forming metal airplane fuselages.

In Fig. 12, I show the forward portion of onetail surfaces 48, ll and I0.

of the block 33, free rotation of which shaft is prevented by its connection to a torsion spring 4| ah ownin Fig. 3. The spring ll is also connected'io a plate I attached to block 33 by of bolts 42. I B-to 11 inclusivethe block It is hollowed at 43 and slotted at It the length of the hollow 3. Thus three thin walls l5, l5 and I! are formed around the hollow 42 as shown in Figs.7,9and1l. I

8 and 5m the vertical'fin 48. a portioni is shown in Figs. 6, to 10, inclusive.

Figs. 7', 9 and 11, I show a portion of the a portion of the horizontal fins stand II. To assist in forming these fixed tail surfaces, l8, l0 and II, thesheath l4 terminates its tail section into thin hollow fins or bladders ll, 52

and '53, of such shape and size asto fit 'loomly and nearly fill the interior of the preformed fixed In Fig. 5 is shown bladder I expanded under forming pressure, the nature of which will be described later. 54 is a rope or flexible metal cable attached to the tip 55 of the bladder Ii. Cables It and 51 shown with-cable N in Figs. 6, 8, l0 and 11, are likewise attached respectively to bladders l2 and it. From the-fully expanded positions of the bladders II, I2 and I3 as shown in Fig. 11, the cables 54. II and I! are attached at their respective ends II, I. and CI to theshaft l0.

the method of forming the bladders It along with the sheath "ll is not tail surfaces 40, u and n, as... in Figs. 5,

'10 and 11. 'I'heshell I8 withthefixedtaflsurdirection shown by the arrow 1| of Fig. 7, to roll the cables 84, 58 and 51, followed by the bladders 5|, 82 and 83, upon the shaft 38. The bladders 8|, 82 and 83 in rolling upon the shaft 38 along with the contraction, of the sheath .34 force the fluid -"ftom theapparatus mold and the sheathed block. The fuselage .metalwill then age at room temperature to its maximum strength.

Wino construction Referring to the drawings, Figs. 15, 17, 18a and 18b show a metal block 8| covered by a sheath 82 made of the elastic material of casing 34 described above. Shown in Fig 15 and 17 is a pipe '83 with a flange or face plate 84 attached by means of bolts 85 to the block 8| to compress the sheath 82 against the block 8| as shown in Fig. 17. 85 is a hole passing through the sheath 82 and partly into the block 8|, while 81 is a hole passing through the block 8| and through hole 88 as shown in Fig. 17.

A Duralumin form or shell 88 is placed over the sheath 82 as shown in Figs. 15, 17 and 18a. The form or shell 88 is of the approximate shape but smaller than that of the finished wing 88 shown in Fig. 16, with, its section seams 88 welded, worked, 1'7 and 18a, and the shell 88 solution heat treated as described above. I

Referring to the drawings, Figs. 16, 1'7, 18a and 18b show a mold 88 split longitudinally into two parts. The interior of the molds 88 has the shape of the finished wing 88 shown in Fig. 16, with a groove 8| around its interior as shown in Fig. 17. Passing around the mold 88 are flanges 82 as shown in Figs. 15, 18a and 18b.

To form the shell or wing 88, the mold 88 is placed over the form or shell 88, the face plate 84 fitting into the groove 8| as shown in Fig. 17. The two parts of the mold 88 are then secured together by clamps 83 engaging the flanges 82 as shown in Figs. 15, 18a, 18b.

Fluid 84, preferably water, is then forced through the pipe 83, and the holes 88 and 81 to expand the sheath 82 which in-tum expands the shell 88 against the interior surfaces of the mold 88 as shown in Fig. 18b. A further increase in pressure forces the shell 88 against the cutting edges 85 of the groove 86 as shown in'Flgs. 18a and 18b to cut the metal to form an'opening for an aileron (not shown). Fig. 17 shows a groove 81 with a cutting edge 88 for trimming the root of the shell 88.

The forming of the wing 88 having been completed, the pressure is released, whereupon the sheath 82 contracts to' force he fluid 84 from the apparatus, after which the f rmed wing 88 shown in Fig. 16 is removed from t e apparatus.

In Fig. 19, I show the forward portions of a block 88, sheath 34, shell 38' and half of the mold 28. The block 88 differs from the block 33 shown in Fig. 3 in that a pipe I88 forms an integral part of the block 88. It is otherwise the same. A ring I8| fitting into the groove 32 of the die 28 is connected by means of bolts 38 passing through thesheath 34 to the face I82 of the block 88.

The primary function ofv the bolts 38 is to keep the mold 28 in proper relationship to the rolled, and beveled as shown in Figs.

34, the solution heat treated shell 28, with the cutting edge 18 of the groove 11.

block 88, .by-preventing. rotation of the ring III about the pipe I88. The pressure exerted by the bolts 38 on that portion of the sheath 84 between the ring I8| and the face I82 of the block 88 amounts to only a small part of the total pressure on the above mentioned portion of the easing. It will, therefore, be disregarded in order to better understand the effect ofthe major forces involved in the operation of the apparatus. A further clarification and simplification results when the sheath 34 and the shell 38 are thought to be removed and the mold 28 forming with the ring I8| a fluid-tight container free to move in a fore and aft or horizontal direction on the pipe I88, with no loss of pressure between the ring I8| and the pipe I88. It will be perceived that this hypothesis is valid in that-it reproduces in effect the major forces involved in the operation of the apparatus.

A force equal to the product of the pressure and the area of the face I82 tends to move the block 88 to the right. A force equal to the product of the pressure and the total frontal area of the block 88 (which includes the area of the pipe I 88) tends to move the block 88 to the left. The diflerence amounts to a force equal to the product of the pressure and the area of the pipe I88. By area ofthe pipe I88, I mean the area of the circle whose diameter is that of the external diameter of the pipe I88.

Thus it is seen in referring to Fig. 19, that in the operation of the apparatus, a force varying with the pressure 34 between the ring I8| and the face I82 of the block 88.

If so desired, a suitable cement or bonding agent may also be used on the surfaces of the abovementioned portion of the casing.

In Figs. 28, 21 and 22 are shown enlarged sectional views of a portion ofthe block 33, sheath 38, and mold At 13-is a seam, welded, worked rolled, and beveled prior to heat treatment of the shell 38.

Fig. 20 shows the shell 38 before forming. In Fig. 21, I show the sheath 34 expanded by the fiuid 15 under pressure. The expansion of the sheath 34 against the shell 38 creates ten- 50.

sile stresses in the shell 38 on both sides of the beveled seam 13. The lines of action of the resultants of these stresses pass through the centers of gravity of the sections, that is, through the center of the material of theshell 38. The resultants of these stresses designated 'as -P, shown in Fig. 30, are of equal magnitude and opposite direction, at a distance d apart. Thus resultants P constitute a couple of moment Pd.

Since the material of the shell 38 is thin, and therefore, of low fiexural strength, an increase in the pressure upon the sheath 34 ,will produce higher stresses within the shell 38 resulting in a progressive decrease in d until the shell in the way of the beveled seam 13 becomes straight as shown in Figs. 21 and 22. A. second factor tending to straighten the material in the way of the seam 13 is the direct pressure of the sheath 34 upon the shell 38, resulting in the flattening of the material in theway of the seam 13, against the mold 28.

As shown in Figs. 21 and 22, the cutting of the shell 38 results from the pressure of the sheath 34 upon the shell 38 creating a tension in the shell 38 above the groove 11 in combination. with a concentration of shearingstress in the shell of the block' 88- acts to compress the sheath,

(shown in Fig. 13) is removed from block 33 is then attached to the face plate 3| by means of bath 'ofrubber intended'as part of my inventionas set forth in the appended cIaimsIit' may nevertheless prove helpful to describe such a method. 1 In' Fig. 13, I- show the forward portion of the block 33 with the shaft'39-inserted and-the torsion spring 49 attached only-to the shaft 39, which is thus free to rotate but is restrained from motion in a foreand aft direction by a shaft 6| fitted into the hole 36 (shown in Fig. 3) of the block 33. Shaft 6| is provided with a flange 62 shouldered at 63 to a depth equal to the desired thickness of the sheath 34 and is secured to the block 33 by means of bolts 35 (shown in Fig. 3). Holes 31 are plugged by thin discs 64 made preferably of plaster of Paris;

Fig. 14 shows the tail end of the block 33 with the shaft 39 and the cables 54, 56, and 51 attached thereto. 65, 66 and 61 are thin walled hollow forms made preferably of plaster of Paris, upon which may be deposited rubber latex or the like to form the bladders 52 and 53. Cables 56, 56 and 51 are threaded through the tips 68 of the forms 65,66 and 61, after which the forms 65, 66 and 61. are securely socketed into the slots 44 of the block 33 (shown in Figs. 7,9 and 11).

The cables 54, 56 and 51 are next cutto the desired length and the strands unraveled extending beyond the tips 68 of the forms 65, 66 and 61. The unraveled strands are then bent back close to the surface of the forms 65, 66 and 61 to anchor the cables 54, 56 and 51 to the sneath 34, as shown at 69 and 10.

The block 33 with its attached forms 65, 66 and 61 is then dipped into a bath of rubber latex or the like and the operation repeated until the sheath 34 and bladders 5|, 52 and 53 have been built to the desired thickness.

After the sheath 34 and bladders 5|, 53 have been thoroughly dried, the shaft 6| the block 33,

and the bolts 35 (shown in Fig. 3). position with Block 33 is next placed in a vertical the tail end up and the casing 34 inflated, preferably by air, through pipe 30. The forms 65, 66

@and 61 are broken into small pieces within the These pieces of plaster downward and forbladders 5|, 52 and 53. having been shaken to the ward end of the block 33 may then be removed along with the plaster discs 64'merely by disconnecting the face plate 3| and stretching the sheath 34 away from the forward end of the block 33. The block 33 is then placed in a vertical position with the tail down and the bladders 5|, 52 and 53 inflated by water poured through the hole 36 of the block 33.

Following this, the plate 4| is connected to the torsion spring 49 (shown in Fig. 3) and the shaft 39 rotated through the spring 40 by rotating the plate 4| in the direction shown by the arrow 1| shown in Fig. 7. Thus the cables 54, 56 and 51 followed by the bladders 5|, 52 and 53 pulling against the water pressure indicated by the arrows 12 of Fig. 9, are rolled onto the shaft 39. With the bladders 5|, 52 and 53 tightly wound about theshaft 39 as shown in Fig. '7, the plate 4| is then secured to the block 33 by means of bolts 42 as shown in Fig. 3.

Following this, the face plate 3| is attached to the block 33 by means of bolts 35 as shown in Fig. 3, and the apparatus is then ready for use. I

Disc 64 and forms 65, 66 and'61 may also be made of gelatine. The sheath 34 and the bladders 5|, 52 and 53 are formed by'dippin'g'into a 52 and I 3 latex-{or the lik as described above.

- After the sheath 34 and bladders 5|, 5: and s: have been thoroughly dried, the sheath 34 is inflated with hot" water and the block 33 immersed in hot'water to dissolve the gelatine discs 64 and gelatine forms 65, 66'and 61.

In the preferred'practice of my invention, the airplane is made of Duralumin. For a fuselage such as shown in Fig. 3, the sections comprising the shell are cut from annealed Duralumin and formedon a bending brake. They are then placed in position on a jig (not shown) of a shape similar to that of the block 33 shown in Fig. 3, and resistance spot welded to each other only where necessary to hold the sections in position. The jig has upon its surface bars or platens of hard copper alloy and .are located under the lapped joints or seams of the sections. The purpose of the platens is to carry the electric current used in welding the seams.

The seams 13, shown in Figs. 3 and 4b, are re sistance welded continuously throughout their.

length by means of a hard copper alloy rollerelectrode.

Following the welding electrode is another roller carrying an electric current of less than a welding amperage to apply heat and pressure to work the welded seams 13 to reflne the grain structure of the weld metal. I term this a wor rolling operation.

Following the "working roller is a milling cutter used to bevel the seams 13.

The sections comprising the fins 48, 49 and shown in Figs. 3, 5, and '7 to 11 inclusive, are

formed to their approximate finished shape, after which their seams are welded, "work rolled, and beveled as in the case of the shell. The fins 48, 49 and 56 are then welded to the fuselage iorm at 14, the seams being worked and beveled as described above and shown in Fig. 3.

These operations are-continuous in that they follow each other in rapid order.

The shell or form is then solution heat treated,

; after which it is placed over the sheath block 33 as shown in Figs. 3 and 4a. The halves of the mold 26 are brought together, the face plate 3| fitting into the groove 32 of the mold 26 as shown in Fig. 3. The halves of the mold 26 are then secured together by clamps 29 as shown in Figs. 3, 4a and 4b. Referring to Fig. 3, a fluid 15, preferably water, is forced under pressure through pipe 30, and holes 36 and 31, to expand the casing 34 against the shell or form 38. In this way shell 38 is in turn expandedto take the shape of the interior of the mold 26 as shown inFig.4b. v

Further pressure is then applied to force the shell 36 against the cutting edges 16 of the grooves 11 and against the cutting edges 16a of the recesses 11a, shown in Figs. 3, 4a, 4b and 12 to part the metal alongthe cutting edges 16 and 16a as shown in Fig. 3b, to form the opening for the windshield, doors, flanges 18 to engage the wing and other necessary holes as shown in Fig. 2. Thus door panels 19 are also formed.

Simultaneously, the fins 43, 49 and 59, are formed as shown in Figs. 5, and 6 toll inclusive. The fluid 15 exerts a'pressure on the bladders 5|, 52 and 53 as 'indicated'by thearro'ws shown in Fig. 9, which rotates the shaft 44 in the direction of-the arrows-12; The rotation of the shaft 44 reacts; against the torsion spring 40- 'shown in Fig. 3. With'an increase in pressure thebladders 5|,] 52 and 53 expand to expand in turn the fixed 38 along the cutting edge I6. These combined stresses serve to part or cut the shell 38 along the cutting edge I6.

In the same way, the door panel I9 shown in Fig. 4b is cut from the shell 38.

In the same manner, as described above, is accomplished the straightening of the material in the way of the beveled seams 89 and the cutting of the wing shell 81 shown in Figs. 1'7, 18a. and 18b.

In Figs. 23, 24a and 2417, I show a mold I03 cut at I04. Fitting closely within the door shaped opening thus formed is a movable section I05 limited in inward motion by a flange I06 around the periphery of the movable section I05 and bearing against the mold I03 to form with its face I01 a fair surface with the interior of the mold I03 as shown in Fig. 24a.

In Figs. 24a and 2417 are shown portions of the block I08, sheath I09 and shell H0, all of which are similar to the block, sheath, and shell previously described and shown.

The sheath I09 is inflated by the pressure of a fluid I II to expand the shell I I0 against the wall of the mold I03 and the face I01 of the movable section I 05, the air between the shell H0 and mold I03 escaping between the fairing surfaces of the flanges on the half molds.

At this point a liquid lubricant H2 is forced into the hole I I3 of the mold I03 passing through a narrow slot H4 in a shaped plate H5 to thoroughly lubricate the interior of the mold I03.

Increased pressure draws the shell H0 to form a bulge H6 forcing the lubricant H2 to flow between the shell IIO and the interior of the mold I03, the lubricant H2 escaping between the fairing surfaces of the flanges on the half mold.

Further increase in pressure further expands the bulge H6 until the shell H0 is out along the cutting edges H'I adjacent to the grooves H8 and I I 9 to form the shell upon the fairing shaped surfaces 120 and HI of the mold I03, leaving a scrap piece I22 pressed against the plate H5 as shown in Fig. 24b.

The movable section I05 is then moved outwardly to provide cutting edges I 23 on which the shell H0 is cut to form an opening for a door while simultaneously forming a door panel I24.

Except for the portion described above, the

mold I03 is similar to the mold 26 shown in Figs.

l and 3 to 11 inclusive. However, mold 26 would be unsuitable for the forming of a deep drawn fairing section such as described above, because of the tendency of the shell to tear on the sharp cutting edges 16a of recess 'I'Ia shown in Figs.

4a, 4b and 12.

It will thus be seen that in addition to affording a novel and efllcient method of forming hollow members into desired shapes and forms, the same means and method may :be employed for punching out pieces of metal therefrom; that by my means and method an airplane fuselage together with wing roots and vertical and horizontal fins Ian maybe turned out as a unit through a single expanding or forming operation; that, in addition, the same process and means enables me to punch out windows, doors, etc. simultaneously with the formation of the fuselage. Employing substantially the same means and method, whole wing sections may be formed, as well as other parts or portions of airplanes.

While I have shown and described my method of forming all welded metal airplanes, I wish it understood that I do not confine myself to the precise details of construction as hereinabove set forth by way of illustration, or the precise method as thereina'bove set forth, for it is apparent that changes and variations may be made, not only in the structure 'but in some details of the method. Although I have shown a fuselage and wing with smooth exteriors, my invention is not limited to this design. For example, load-carrying elements such as ribs, corrugations, or the like, may be formed upon the fuselage and wings.

Neither do I want to limit myself to the manufacture by my method of airplanes alone, since this method may be used in forming other objects of thin welded metal. Any variations that may be made without departing from the spirit of the invention is contemplated by theappended claims.

I claim:

1. In combination, a hollow'mold having an opening in a wall thereof circumscribed by cutting edges, a movable section fitting into said opening, a preformed block encased by an elastic sheath disposed within said mold, and means for inflating said sheath with afluid under pressure whereby said sheath will expand a metal shell into conformity with the inside of the mold and where said shell comes into contact with the cutting edges of said opening, the metal thereof is severed to remove a part corresponding to the opening, the movable section being moved outwardly by the operation to provide the said cutting edges.

2. In combination, a hollow mold provided with hollow fins, a preformed block encased by an elastic sheath disposed within said mold, said block having a deep hollow with slots in the body thereof in juxtaposition to said, hollow fins, and said sheath having communicating bladder appendages in number corresponding to the number of fins, a revoluble shaft extending through said block and across said hollow, means for rotating said shaft and means connecting said bladders to said shaft whereby the bladders may be wound on said shaft, and means for inflating said sheath and bladders with a fluid under pressure.

3. The combination in accordance with claim 2, wherein the block is provided with a main communicating passage extending from the fluid supply means and auxiliary passages extending to the inside of said sheath. Y

CHARLES A. JOHNSON. 

